Repair manual
Wiring diagrams
Volvo S40 I facelift Repair Manual
Step-by-step repair and maintenance instructions for the Volvo S40 I facelift (1999–2004): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
98sections
1784articles
ENManual language
- Preparations
- Replacing switches
- Ignition switch
- Light switch
- Hazard warning signal flasher
- Mode selector switch, automatic transmissions
- Trip computer
- Power sun roof
- Front door module
- Rear door module
- Child-Proof Lock
- VGLA Sensors
- Replacing the DSA switch
- Removing
- Conditions
- Programming general
- Ordering/programming immobilizer function
- Ordering/programming remote control function
- Final check
- Information
- Ordering software/key
- Control module, initiating
- Immobilizer control module
- Immobilizer control module, initiating
- Install central electronic module (CEM)
- Install lower panel, drivers side
- Install the tailgate washer pump
- Install the washer reservoir
- Tailgate washer
- Replacing front nozzle
- Install the headlamp wiper arm
- Installing the tailgate wiper motor
- Windshield wiper arm
- Installing glass breakage sensor
- Finishing work
- Installing the LED (VGLA)
- Preparation
- Preparations
- Removing the fender liner
- Installing the fender liner
- Removing tilt sensor
- Installing tilt sensor
- Installing control module
- Installing VGLA-control module
- Ordering software
- Electric motor fuel tank filler cover, replacing
- Preparatory work
- Removing electric motor
- Install the electric motor
- Installing the mounting for the motor
- Removing the fuel tank filler cover
- Fuel tank filler cover
- Removing motor
- Installing motor
- Installing motor bracket
- Removing/Installing Side Panels In the Cargo Compartment, V40
- Fuel tank filler cover motor
- Installing the central locking motor for the front side door
- Installing the central locking unit
- Installing the window guide rail
- Installing the door insulation
- Installing the central locking for the motor tailgate or trunk lid (S40/V40)
- Removing and installing the door module switch in the front side door
- Install switch
- Removing the lock for the front side door
- Installing the lock for the front side door
- Installing the lock cylinder, driver's door
- Installing the lock cylinder, passenger door
- Installing the lock switch, driver's door
- Removing the lock for the rear side door
- Installing the lock for the rear side door
- Removing the door insulation
- Removing the window guide rail
- Installing the inner lock mechanism
- The switch for the child-proof lock
- Installing the switch
- Installing trunk/tailgate switch
- Installing the lift mechanism
- Removing the insulation
- Removing the inner lock mechanism
- Replacing operating switch
- Finishing
- Removing the door opener handle
- Lock switch in door lock, driver's door, removing
- Lock cylinder without lock switch, installing/removing
- Lock cylinder with lock switch, installing/removing
- Lock switch driver's door, installing
- Installing the door opening handle
- Doors, adjusting
- Door hinges front door, replacing
- Removing rear door panel
- Removing window guide rail
- Installing guide plate
- Installing handgrip
- Installing window guide rail
- Installing insulation
- Installing rear door panel
- Removing rear door window mechanism
- Install the headlining
- Installing the rear interior lighting, 5 door models
- Installing the cover for the high-mounted stop lamp, 4 door models
- Installing the C-post panel
- Installing the D-post panel, 5 door models
- Installing the front grab handle
- Installing the B-post panel
- Installing the A-post panel
- Installing the sun visor and holder
- Installing boot lid lock mechanism
- Installing boot lid lock cylinder
- Seals
- Replacing the tailgate
- Installing the tailgate
- Adjusting doors
- Installing and removing rear door hinges
- Tailgate components, changing
- Fitting the rear light unit
- Changing the fuel filler flap
- Installing the trunk lid
- Installing the hinges for the trunk lid
- Replacing Gas Struts
- Adjusting the trunk lid
- Removing the guide rails for the windows
- Inner lock unit front, installing
- Installing the guide rails for the windows
- Removing central locking motor trunk (S40)
- Installing central locking motor trunk/tailgate (S40/V40)
- Door switches
- Removing/installing switch(es) on dashboard console
- Removing the handle
- Installing the handle
- Install the door panel
- Trunk/tailgate switch
- Replacing glass breakage sensor
- Hood catch with and without switch
- Receiver
- Installing wheel arch
- Tilt sensor
- Installing A post panel
- Ultrasonic or glass breakage control module
- VGLA-control module, removing
- VGLA-control module, installing
- Software, ordering
- Installing the mechanical cable
- Removing the hinge front side door
- Installing the hinges for the front side door
- Removing the hinge for the rear side door
- Installing the hinge for the rear side door
- Removing door panels
- Installing a used run-off profile on the front side door
- Installing a used run-off profile on the rear side door
- Installing door panels
- Removing the front door stop
- Installing the front door stop
- Removing the door stop for the rear side door
- Installing the door stop for the rear side door
- Checking/replacing operating switch
- Control unit, replacing/installing
- Removing/installing motor
- Removing/installing sun shade
- Sliding and tilting sun roof
- Replacing the components for the tailgate
- Removing the tailgate lock cylinder
- Installing the tailgate lock cylinder
- Installing the lock mechanism for the tailgate
- Installing the tailgate panel
- Removing hinges
- Installing hinges
- Brake Control System - General Diagnostics and Tests (644 Body) 5
- Brake Control System - Removal, Replacement and Installation (644 Body) 3
- Brake Control System - Symptom Related Diagnostic Procedures (644 Body) 2
- Anti-Lock Brake System (ABS) Diagnostic Trouble Codes (644 Body) 4
- Brake Control System - Cleaning, Inspection and Adjustment (644 Body) 2
- Brake Control System - Design and Function (644 Body) 3
- Brake Control System - Specifications, Electrical/electronic (644 Body)
- Brake Control System - General Safety Information (644 Body)
- Brake Control System - General Information (644 Body) 2
- Brake Control System - Component Location (644 Body)
- Anti-Lock Brake System (ABS) - Diagnostic Trouble Code (DTC) Index (644 Body)
- ABS Modulator/control Module - Removal & Installation (644 Body)
- Brake Control Module (BCM) & Anti-Lock Brake System Module Connector - Repair (644 Body) 2
- Automatic A/c-Heater Systems - S40 (644 Body) & V40 6
- Climate Units - General Diagnostics and Tests (644 Body) 6
- Climate Units - Specifications, Electrical/electronic (644 Body) 3
- Climate Units - Removal, Replacement and Installation (644 Body) 3
- Climate Units - Cleaning, Inspection and Adjustment (644 Body) 4
- Climate Control Module (Ccm) & Electronic Climate Control (Ecc) - Diagnostic Trouble Codes (644 Body) 4
- Climate Units - Design and Function (644 Body) 3
- Electronic Climate Control (Ecc) Diagnostic Trouble Codes (644 Body) 4
- Electronic Climate Control (Ecc) & Heater Module (Hea) Diagnostic Trouble Codes (644 Body) 4
- Climate Units - Symptom Related Diagnostic Procedures (644 Body) 5
- Climate Units - General Information (644 Body) 6
- Climate Units - General Safety Information (644 Body) 2
- Climate Units - Specifications, Mechanical (644 Body)
- Climate Units - Component Location (644 Body) 2
- Climate Control Module (Ccm) - Diagnostic Trouble Code (DTC) Index (644 Body)
- HVAC - Maintenance, Removal & Installation (644 Body) 6
- HVAC Mode Selector - Removal & Installation (644 Body)
- Transmission - General Diagnostics and Tests (644 Body) 3
- Transmission - Removal, Replacement and Installation (644 Body) 7
- Transmission - Cleaning, Inspection and Adjustment (644 Body) 3
- Transmission - Specifications, Other (644 Body) 3
- Transmission - Specifications, Electrical/electronic (644 Body)
- Transmission - Design and Function (644 Body) 3
- Transmission Control Module (TCM) Diagnostic Trouble Codes - 1 of 2 (644 Body) 6
- Transmission Control Module (TCM) Diagnostic Trouble Codes - 2 of 2 (644 Body) 5
- Transmission - Symptom Related Diagnostic Procedures (644 Body) 7
- Transmission - General Information (644 Body)
- Transmission - Component Location (644 Body)
- Transmission Control Module (TCM) - Diagnostic Trouble Code (DTC) Index (644 Body)
- Transmission Cable - Adjusting (644 Body) 4
- Transmission Mechanical & Lubrication - Removal, Installation, & Inspection (644 Body) 4
- Transmission - Installation (644 Body) 4
- Wiring & Connector Terminals - General Diagnostics and Tests (644 Body)
- Cables and Fuses - General Diagnostics and Tests (644 Body) 2
- Central Electronic Module (Cem) - Specifications, Electrical/electronic (644 Body)
- Breakout Box, Wiring & Terminals - General Diagnostics and Tests (644 Body) 2
- Central Electronic Module (Cem) Diagnostic Trouble Codes (644 Body) 3
- Central Electronic Module (Cem) - Vehicle Communication Information (644 Body)
- Cables, Fuses & Central Electronic Module (Cem) Components - Removal, Replacement and Installation (644 Body) 3
- Wiring & Connector Repair - General Information (644 Body) 5
- Cables and Fuses - Specifications, Mechanical (644 Body)
- Cables and Fuses - Symptom Related Diagnostic Procedures (644 Body) 3
- Central Electronic Module (Cem) - Design and Function (644 Body) 3
- Cables and Fuses - General Safety Information (644 Body)
- Electrical Testing & Diagnosis - General Safety Information (644 Body)
- Central Electronic Module (Cem) - Component Location (644 Body)
- Body Electrical & Battery - Removal & Installation (644 Body) 2
- Connectors, Terminals & Wiring - Repair (644 Body) 5
- Outside Temperature Sensor - Removal & Installation (644 Body)
- Body Electrical - Parameters (644 Body)
- Central Electrical Unit Engine/transmission Control Module Connector (Ecm/tcm) - Repair (644 Body) 2
- Central Electronic Module (Cem) - Diagnostic Trouble Code (DTC) Index
- Preparations
- Fuel tank, replacing
- Fuel tank filler cover
- Rear section
- Bodywork Dimensions
- Replacing the end panel
- Installing the engine mounting/transmission mounting
- Replacing the frame member
- Replacing the front side member
- Replacing the front wheel arch
- Removing the front wheel arch
- Replacing the front wheel arch reinforcement
- Installing the front of the wheel arch reinforcement
- Replacing the lower radiator member
- Installing the lower radiator member
- Replacing the support bracket for the hood catch
- Upper radiator member
- Installing the upper radiator member
- Removing the end panel
- Installing the end panel
- Removing the Engine Mounting/Transmission Mounting
- Removing the frame member
- Installing the frame member
- Removing the front side member
- Installing the front side member
- Installing the front wheel arch
- Removing the front of the wheel arch reinforcement
- Removing the lower radiator member
- Removing the support bracket for the hood catch
- Installing the support bracket for the hood catch
- Replacing the upper radiator member
- Removing the upper radiator member
- Removing the rear fender
- Roof Arch
- Roof Panel
- Removing the roof
- Installing the roof when bonding
- Installing the roof when welding
- Removing the A-post
- Installing the side member reinforcement
- Installing the A-post reinforcement
- Installing the B-post reinforcement
- Installing the inner section of the B post
- Removing the outer door sill
- Installing the reinforcement for the door sill
- Installing the A-post
- Replacing door panels
- Replacing side member reinforcement
- Replacing the A-post outer cowl side
- Removing the A-post on the outer cowl side
- Installing the A-post on the outer cowl side
- Removing the A-post reinforcement
- Removing the A-post reinforcement on the cowl side
- Installing the A-post reinforcement on the cowl side
- Removing the B-post reinforcement
- Removing the inner B-post
- Removing the outer B-post
- Installing the outer section of the B post
- Installing the door sill
- Removing the reinforcement member for the door sill
- Information
- Battery and Mounting - General Diagnostics and Tests (644 Body) 2
- Battery and Mounting - Service (644 Body) 3
- Battery and Mounting - Specifications, Other (644 Body)
- Charging & Starting - Symptom Related Diagnostic Procedures (644 Body) 4
- Battery and Mounting - Design and Function (644 Body)
- Battery and Mounting - General Safety Information (644 Body)
- Battery and Mounting - General Information (644 Body)
- Battery and Mounting - Removal, Replacement and Installation (644 Body)
- Alternator and Regulator - Removal, Replacement and Installation (644 Body) 2
- Battery - Installation (644 Body)
- Generator - Removal & Installation (644 Body)
- The Center Ventilation Vents In the Dashboard
- Installing the Center Ventilation Vents
- Installing the Ventilation Vent On the Driver's Side
- Installing the Ventilation Vent On the Passenger Side
- Installing the Control Module
- Finishing
- General
- Replacing Condenser
- Filling With Refrigerant
- Replacing the Evaporator
- Replacing the Expansion Valve
- Installing the Filter
- Installing the Heat Exchanger
- Replacing the Intermediate Section On Cars With Air Conditioning (A/C)
- Replacing the Resistor On Cars Without Air Conditioning (A/C)
- Design
- Comfort Module
- Preparations
- Removing the Comfort Module
- Installing the Comfort Module
- Finishing Work
- Installing the Damper Motor Housing For Air Distribution
- Installing the Engine Coolant Temperature (ECT) Sensor
- Evaporator, Replacing
- Removing Expansion Valve
- Installing Expansion Valve
- Removing the Heat Exchanger
- Disconnect the heater unit
- Removing the Interior Temperature Sensor
- Installing the Interior Temperature Sensor
- Installing Outside Temperature Sensor (Only Cars With ECC)
- Removing Passenger Compartment Fan Housing
- Installing the Passenger Compartment Fan Housing
- Power Unit Blower Fan
- Preparatory Work
- Installing Power Unit Blower Fan
- Installing the Temperature Damper Motor
- Installing Temperature Sensor Evaporator (Only Cars With ECC)
- Magnetic Clutch
- Spacer Ring
- Dashboard Environment Panel
- Installing the dashboard environment panel
- Installing the Control Cable
- Installing the Control Panel
- Replacing Pipes And Hoses
- The Hose/Pipe Between the Compressor And the Evaporator
- The Pipe Between the Evaporator And the Swivel Connection On the Firewall
- The Pipe Between the Swivel Connection And the Receiver Drier On the Firewall
- The Pipe Between the Receiver Drier And the Condenser
- The Hose Between the Compressor And the Compressor
- Replacing Pressure Switch
- Replacing Receiver/Drier
- Transfer the Support To the New Drier
- Important Information
- Final Check
- Installing Air Baffle
- Installing Components
- Quick-Release Fuel Line Connector
- Flame Sensor And Connector
- Atomizer And Fuel Injection Nozzle
- Cables
- Heater
- Fuel line
- Removing Bumper
- Engine Coolant Hoses
- Removing Heat Exchanger
- Removing the Bumper
- Control Module
- Fuel Pump And Fuel Line
- Water Pump
- Installing the Evaporator Temperature Sensor
- Sun Sensor
- Replacing the Ventilation Vents On the Passenger Side
- Replacing the Central Ventilation Vents
- Compressor
- Change Pressure Monitor
- Condenser
- Install the Condenser
- Electromagnetic Clutch
- Pipes And Hoses
- Install Pipe
- Replacing Coolant
- Fill with coolant
- Receiver Drier
- Dryer, Removing
- Transfer the Support To the New Dryer
- Accumulator/Dryer, Installing
- Cable Terminals box, p/n 9814232
- Cable Terminals Kit, p/n 9814233
- Cable Terminals Kit, p/n 9814234
- Connecting the measuring tool connector
- Conditions
- Disconnecting the measuring tool connector
- Replacing the engine control module (ECM)
- Connector, data link connector (DLC), repair
- Data link connector (DLC), dismantling
- Secondary lock
- Connector, door, repair
- Primary lock
- Connector, fuse holder, repair
- Preparatory work
- Finishing work
- Connector, relay box, repair
- The secondary lock
- Connector, sealed with secondary lock, repair
- Connector, dismantling
- Primary locking
- Connector, sealed without secondary lock, repair
- Connectors, repair (1 Of 10)
- Secondary locking
- Connectors, repair (2 Of 10)
- Connectors, repair (4 Of 10)
- Connectors, repair (9 Of 10)
- Connectors, repair (10 Of 10)
- Connectors, repair (8 Of 10)
- Connectors, repair (3 Of 10)
- Connector anti-lock braking system module (ABS)
- Connector type 1
- Connector type 2
- Connector type 3
- Connector type 4
- Connector type 5
- Connector type 6
- Connector type 7
- Connector sealed type 1
- Dismantling
- Connector sealed, type 2
- Connector sealed, type 3
- Joining cables
- Connecting
- Junction sleeve
- Selection of repair kit, SRS system
- Removing the battery lead and the ignition cable
- Securing the cable for the SRS system
- Installing the battery lead
- Checking and adjusting the SRS system
- Pulley and freewheel, generator, replacing
- Crimp tool
- Immobilizer, Lock & Alarm - General Diagnostics and Tests (644 Body) 2
- Alarm, Doors and Lids - Removal, Replacement and Installation (644 Body) 6
- Programmable Parameters - Specifications, Electrical/electronic (644 Body) 4
- Accessories & Equipment - Removal, Replacement and Installation (644 Body) 3
- Doors and Lids - Checking Wiring and Terminals (644 Body)
- Guard Lock and Alarm (Gla) & Immobilizer Module (Imm) Diagnostic Trouble Codes (644 Body) 4
- Alarm, Central Locking, Turn Signals - Symptom Related Diagnostic Procedures (644 Body) 5
- Alarm, Immobilizer & Lock - Design and Function (644 Body) 4
- Immobilizer - Specifications, Other (644 Body)
- Central Locking System - General Information (644 Body)
- Alarm, Central Locking & Immobilizer - Component Location (644 Body)
- Doors and Lids - Cleaning, Inspection and Adjustment (644 Body)
- Guard Lock and Alarm (Gla) - Diagnostic Trouble Code (DTC) Index (644 Body)
- Immobilizer Module (Imm) - Diagnostic Trouble Code (DTC) Index (644 Body)
- Key - Adding/deleting (644 Body)
- Replacing spark plugs
- Removing spark plugs
- Installing spark plugs
- Installing the idle air control (IAC) valve
- Installing the mass air flow (MAF) sensor
- Installing the turbocharger (TC) control valve
- Install the cover on the timing gear
- Replacing the idle air control (IAC) valve
- Replacing the mass air flow (MAF) sensor
- Replacing the turbocharger (TC) control valve
- Replacing the variable valve timing (VVT) control valve
- Replacing the variable valve timing solenoid
- Preparations
- Removing the oil pan
- Cleaning
- Installing the front-rear member
- Replacing the oil and oil filter
- Engine components exhaust side, transferring
- Carrier plate, installing
- Starter motor, Installing
- Removing turbocharged engines with the transmission
- Removing the left-hand side drive shaft nut
- Removing the air conditioning (A/C) hose from the fan shroud
- Removing the left-hand side cover
- Removing the air cleaner (ACL)
- Replacing camshaft seal (retaining ring) front side
- Replacing engine mounting bolsters
- Prerequisites
- Replacing flange plate
- Install flange plate
- Replacing rearmost crankshaft retaining ring
- Removing flange plate
- Installing flange plate
- Replacing the camshaft seals
- Secure the crankshaft position
- Installing timing covers
- Installing the right engine mounting
- Checking work
- Replacing the cover on top of the engine
- Installing the cover on top of the engine
- Replacing the cylinder head and gasket
- Preparation
- Separating the exhaust system
- Removing the manifold and turbocharger (TC)
- Removing the starter motor
- Removing the fuel line
- Removing components
- Installing the lifting beam and lifting hook
- Removing the right-hand engine mounting
- Position the engine according to the marking
- Removing the timing belt
- Removing the timing gear pulley
- Installing the cylinder head
- When replacing or working on the cylinder head
- Installing the valve lifters and camshafts
- Installing the camshaft cover
- Installing the intake pipe for the coolant pump
- Installing the front camshaft seal
- Installing the camshaft timing gear pulley
- Installing the timing belt
- Finishing
- Installing the intake manifold
- Installing components
- Installing the exhaust manifold
- Installing the starter motor
- Replacing toothed (timing) belt
- Align timing gear and crankshaft according to the markings
- Install timing belt at lower side
- Install cover plates
- Install engine bracket
- Install timing gear covers
- Install auxiliaries belt
- Place the hood in the service position
- Automatic transmission: Installing the gear selector mechanism cables
- Fuel hose, routing and connecting
- Charge air hose from the turbocharger (TC), upper hose, installing
- Engine mounting rear, installing
- Front-rear member, installing
- Automatic transmission: Installing the oil pipes
- Lateral strut, installing
- Front wheel, installing
- Air Cleaner (ACL), Installing
- Battery, installing
- Poly V-belts, installing
- Coolant, filling
- VVT-Unit, Replacing/Adjusting
- Removing the variable valve timing (VVT) unit
- Installing VVT-unit
- Installing the timing gear pulley
- Check
- Camshaft seals, replacing
- Removing timing gear covers
- Installing the lifting beam and the lifting hook
- Replacing the camshaft seal
- Installing camshafts' timing gear pulleys
- Installing the timing covers
- Installing the right-hand engine mounting
- Crankshaft seal rear, replacing
- Installing the sealing ring
- Installing the gearbox
- Gearbox, fitting
- Cylinder head/gasket, replacing
- Exhaust manifold, removing
- Starter motor, removing
- Fuel line, removing
- Components, removing
- Inlet pipe, removing
- Timing belt pulley, removing
- Coolant pump's inlet pipe, disconnecting
- Camshaft cover and cylinder head, removing
- Gasket face, cleaning
- Aligning the crankshaft
- Valve depressors and camshafts, installing
- Camshaft cover, installing
- Coolant pump's inlet pipe, installing
- Front camshaft seal, installing
- Camshafts' timing belt pulley, installing
- Right engine mount, installing
- Inlet pipe, installing
- Components, installing
- Fuel line, installing
- Exhaust manifold, installing
- Checking performed work
- Conditions
- Removing the left-hand engine mounting
- Installing the left-hand engine mounting
- Removing the front engine mounting
- Installing the front engine mounting
- Removing the rear engine mounting
- Installing the rear engine mounting
- Replacing the air cleaner (ACL)
- Replacing the oil pump and front crankshaft seal
- Replacing the timing belt
- Removing the auxiliaries belt
- Removing the timing covers
- Tensioning the tensioner pulley and the idler pulley
- Removing the splash guards under the engine
- Removing the timing belt (at the bottom)
- Removing the timing belt and mechanical timing belt tensioner
- Replacing the Dual Mass Flywheel
- Preparatory work
- Removing the flywheel
- Installing the flywheel
- Reinstall the transmission
- Checking/replacing the clutch driven plate and self-adjusting clutch
- Check that there are no cracks or large scratches on the flywheel
- Replacing piston cooling valves
- Ignition and Control Systems - Removal, Replacement and Installation (644 Body) 5
- Ignition and Control Systems - Specifications, Electrical/electronic (644 Body) 3
- Ignition and Control Systems - Component Location (644 Body) 3
- Ignition and Control Systems - Symptom Related Diagnostic Procedures (644 Body) 5
- Ignition and Control Systems - Design and Function (644 Body) 4
- Engine - Inspection and Adjustment (644 Body) 4
- Kickdown Switch & Throttle Cable - Removal, Replacement and Installation (644 Body)
- Accelerator Cable - Cleaning, Inspection and Adjustment (644 Body) 2
- Engine Control - Design and Function (644 Body) 3
- Engine Control - General Safety Information (644 Body) 2
- Engine Control - Component Location (644 Body) 2
- Engine Control Module (ECM) Connector a Terminals - Signal Information (644 Body)
- Engine Control Module (ECM) - Removal & Installation (644 Body) 2
- Engine Control Module (ECM) Readiness Monitor - Description & Operation (644 Body)
- Engine Performance Diagnostic Routine Outline - General Information
- Engine Performance Safety Precautions
- Parasitic Load Explanation & Test Procedures - General Information 2
- Waveforms - Injector Pattern Tutorial - General Information 2
- Electrostatic Discharge Warning - General Information
- State Emission Standards - Diesel
- Media, Communication and Navigation - General Diagnostics and Tests (644 Body) 3
- Audio Module HU1205 - Specifications, Electrical/electronic (644 Body)
- Audio Module (Aum) Diagnostic Trouble Codes (644 Body) 2
- Media, Communication and Navigation - Design and Function (644 Body) 3
- Media, Communication and Navigation - Component Location (644 Body)
- Media, Communication and Navigation - General Information (644 Body)
- Audio Module (Aum) - Diagnostic Trouble Code (DTC) Index (644 Body)
- Media, Communication and Navigation - Symptom Related Diagnostic Procedures (644 Body) 3
- Audio Equipment - Removal, Installation, & Inspection (644 Body)
- Rubber Seals and Seams - Cleaning, Inspection and Adjustment (644 Body) 3
- Steering Column Covers & Interior Panels - Removal & Installation (644 Body)
- Center Console & Glove Compartment - Removal & Installation (644 Body) 3
- Interior Panels & Accessories - Removal & Installation (644 Body) 2
- Headlining & Interior Panels - Removal & Installation (644 Body) 2
- Cargo Compartment & Tailgate Panels - Removal & Installation (644 Body)
Exterior Trim, Glass, Weatherstrips - Removal, Replacement and Installation (644 Body)
36 subsections- Installing door mirrors
- Installing the mirror glass
- Installing the cover
- Installing the control motor and mounting
- Installing the badge
- Installing the plenum chamber
- Trim molding
- Installing the trim molding
- Plenum chamber
- Replacing the rear spoiler S40
- Installing the rear windshield
- Installing components
- Installing Windshields
- PUR
- PUR On Body Flange
- Removing the rear windshield
- Removing components
- Removing the Windshield
- Windscreen, Replacing
- Preparatory work
- Installing the windshield
- Bonded window general, information
- Fixed Side Windows
- Removing Fixed Side Windows
- Installing fixed side windows
- Installing the glass in the front side door
- Positioning the glass
- Installing the guide rail
- Installing the rear license plate holder
- Installing entire door mirror
- Replacing Rear License Plate Holder
- Installing the front sill trim panel and screw
- Installing the sill trim panel with mounting clamps
- Installing the rear sill trim panel
- Roof Trim
- Installing the sill molding
- Fuel System - Removal, Replacement and Installation (644 Body) 6
- Fuel System - Cleaning, Inspection and Adjustment (644 Body) 3
- Ignition and Control Systems - General Safety Information (644 Body)
- Fuel Line - Removal & Installation (644 Body)
- Fuel Injectors & Fuel Pressure - Inspection (644 Body)
- Fuel Level Sensor - Removal & Installation (644 Body) 3
- Fuel Filler Cap - Inspection (644 Body)
- Instrumentation - Connecting Breakout Box (644 Body)
- Instrumentation - Removal, Replacement and Installation (644 Body) 4
- Instrumentation - Specifications, Electrical/electronic (644 Body) 2
- Interior Equipment - Removal, Replacement and Installation (644 Body) 4
- Combined Instrument (Ci) & Driver Information Module (Dim) Diagnostic Trouble Codes (644 Body) 5
- Instrumentation - Specifications, Other (644 Body) 4
- Instrumentation - Symptom Related Diagnostic Procedures (644 Body) 4
- Instrumentation - Diagnostic Functions (644 Body) 4
- Body and Interior - Removal, Replacement and Installation (644 Body) 4
- Combined Instrument Panel - Removal & Installation (644 Body)
- Combined Instrument (Ci) - Diagnostic Trouble Code (DTC) Index
- Installing the (lower) panel on the A-post
- Installing the loudspeaker and loudspeaker grille on the driver's side
- Installing the control panel for the heater system
- Installing the side panel on the center console
- Installing the panel on the dashboard on the driver's side (2000-)
- Removing the dashboard
- Removing the combined instrument panel
- Removing connectors and cables from the dashboard
- Removing the fog lamp relay
- Removing the VGLA relay (unit)
- Removing the ECC unit
- Disconnecting the mechanical control cable for the "airmix" at the end pointing towards the heater
- Removing the (lower) panel from the A-post
- Removing the central electronic module (CEM)
- Disconnecting airbags
- Center console panels
- Comfort module
- Dashboard environment panel
- Installing front center console
- Installing the dashboard
- Installing the loudspeaker and loudspeaker grille on the passenger side
- Installing the dashboard bracket and the hood catch
- Installing components
- Final check
- Installing the rear center console
- Rear center console, components
- Installing the armrest
- Installing the mug holder and the rubber lining
- Installing the 12 volt socket
- Installing the center console locker for the rear center console
- Preparations
- Removing the panels for the dashboard
- Removing the loudspeaker from the dashboard
- Installing the steering column panels
- Transferring components
- Front center console
- Installing the mug holder
- Removing the center console locker from the rear center console
- Steering column panels
- The radio panel
- Transferring dashboard components
- Removing the rear center console
- Installing the front interior lighting
- Replacing the mug holder
- Removing the radio panel
- Installing the radio panel
- Sun visor
- Installing holders
- Installing the mirror
- Front interior lighting
- Rear interior lighting
- Installing the rear interior lighting
- The inner rear view mirror
- Installing the ISOFIX
- Installing GPS antenna
- Preparation
- Installing side impact sensor
- Removing SIPS bags
- Removing the SIPS airbag on the backrest
- Installing the backrest padding
- Installing the SIPS airbag on the backrest
- Installing the plastic base in the backrest frame
- Installing backrest upholstery, general
- Installing the backrest upholstery
- Installing the seat backrest
- Installing head restraints
- Installing seats
- Removing the ventilation vent on the driver's side
- Removing the control panel for the heater system
- Replacing the dashboard
- Installing the instrument panel
- Installing the front center console
- Installing the vent panel
- Installing the console by the radio
- Installing the loudspeakers in the dashboard
- Installing the panels on the underside of the dashboard
- Replacing rear view mirror
- Replacing rear view mirror base
- Replacing the ventilation vents in the dashboard
- Checking and replacing the front seat belts
- Installing the seat belt on the seat
- Replacing the center seat belt
- After a collision in which the SRS system has been deployed
- Supplemental Restraint System Module (SRS), reuse
- Removing the passenger airbag module
- Fitting the dashboard
- Seat belt tensioner
- Checking the function of the seat belts
- Removing the seat belt tensioner on the B-post
- Checking the seat belt tensioner
- Replacing the seat belt tensioner, general
- Installing the seat belt tensioner on the B-post
- Installing new seat belts
- Replacing seat belt buckles
- Replacing sensor module
- Installing center consoles
- Adjusting steering wheel position
- Attach SRS airbag date decal
- Passenger airbag module
- Installing the passenger airbag module
- Finishing work
- Installing SRS airbag date decal
- Replacing the seat belt buckle on the front seat
- Replacing rear seat belt buckles
- Seat belt tensioners, replacing
- Removing the seat belt tensioner
- Installing the seat belt tensioner
- Preparing the vehicle
- Removing the SIPS sensor (B-post)
- Installing the SIPS sensor (B-post)
- Preparing the car
- Installing the SIPS sensor (C-post)
- Installing the B-post seat belt tensioner
- Removing the rear seat belts, 4 door models
- Removing the rear seat belts, 5 door models
- Removing the rear seat belt buckle
- Removing the center seat belt
- Installing the rear seat belts, 4 door models
- Installing the rear seat belts, 5 door models
- Installing rear seat belt buckles
- Installing the center seat belt
- Whiplash element, replacing
- SIPS sensor (B-post)
- SIPS sensor (C-post)
- The front seat belt
- Removing and checking the seat belts for the rear seats
- IC (inflatable curtain)
- Deployed IC (inflatable curtain)
- Battery, disconnecting
- Installing SIPS bags
- General decontamination instructions
- Seat belt buckle
- Removing the control module
- Installing the control module
- SRS ignition cable igniter connector
- S40 V40 model year 2001-2002
- S40 V40 model year 2003-2004
- Steering wheel module and steering wheel
- Installing the steering wheel module
- Fitting the SRS airbag date decal
- Final procedure
- The rear seat belt
- Removing the battery lead and important information
- Finishing
- Removing the driver's airbag (SRS)
- Installing driver's airbag (SRS)
- Cleaning after an airbag has deployed
- Handling non-deployed airbag modules and pyrotechnic seat belt tensioners
- SRS components, replacing
- SRS control module
- Steering wheel contact reel
- Removing the steering wheel
- Installing the steering wheel
- Engine and Engine Components - Removal and Installation (644 Body) 6
- Engine Air Cleaner Housing - Removal & Installation (644 Body)
- Engine Stabilizer Brace - Removal & Installation (644 Body)
- Carrier Plate - Removal & Installation (644 Body)
- Lifting Beam & Lifting Hook on Engine Lifting Eyelet - Installation (644 Body)
- Engine Mechanical Components - Removal & Installation (644 Body) 2
- Hydraulic-Vacuum-Hydraulic Brakes - Removal, Replacement and Installation (644 Body) 6
- Hydraulic-Vacuum-Hydraulic Brakes - Cleaning, Inspection and Adjustment (644 Body) 3
- Wheel Brake - Removal, Replacement and Installation (644 Body) 4
- Wheel Brake - Cleaning, Inspection and Adjustment (644 Body) 2
- Brake & Clutch Pedal - Removal & Installation (644 Body)
- Wheel Brake - Specifications, Mechanical (644 Body) 2
- Vacuum Pump Control Valve & Stop Lamp Switch - Adjustment, Removal & Installation (644 Body) 2
- Transport Protection for Brake Discs - Removal & Installation (644 Body)
- How to Use the Engine Performance Section 8
- Transport, Vehicle Storage and Driving Regulation - Service Programs (644 Body) 2
- Volvo Special Tools & Angle Tightening - General Information (644 Body) 3
- Volvo Vida - Activation of Components/functions (644 Body) 2
- Storage - General Information (644 Body) 2
- Supplemental Restraint System (SRS) - Specifications, Electrical/electronic (644 Body) 2
- Supplemental Restraint System (SRS) Diagnostic Trouble Codes - 1 of 2 (644 Body) 3
- Supplemental Restraint System (SRS) - Component Location (644 Body)
- Supplemental Restraint System (SRS) Diagnostic Trouble Codes - 2 of 2 (644 Body) 3
- Supplemental Restraint System (SRS) Diagnosis & Diagnostic Trouble Codes (644 Body) 4
- Supplemental Restraint System (SRS) - Design and Function (644 Body) 3
- Supplemental Restraint System (SRS) - General Safety Information (644 Body) 3
- Supplemental Restraint System (SRS) Decals - General Safety Information (644 Body)
- Supplemental Restraint System (SRS) - Final Check (644 Body)
- Supplemental Restraint System (SRS) - Diagnostic Trouble Code (DTC) Index (644 Body)
- Contact Reel/steering Wheel Angle Sensor & Driver's Side Airbag - Removal & Installation (644 Body) 2
- Non-Deployed SRS Components - Handling (644 Body)
- Seat Belts & SRS Components - Removal & Installation (644 Body) 5
- Supplemental Restraint System (SRS) Module Connector & Harness - Repair (644 Body) 2
- Seats - Wiring & Terminals (644 Body)
- Seats & Interior - Removal, Replacement and Installation (644 Body) 5
- Whips (Whiplash Protection System) - Design and Function (644 Body)
- Whips (Whiplash Protection System) - Cleaning, Inspection and Adjustment (644 Body)
- Child Seat - Installation Instructions, Accessories (644 Body) 2
- Child Seat, Interior Equipment - Installation Instructions, Accessories (644 Body)
- Center Head Restraint & Backrest Catches - Removal & Installation (644 Body)
- Side Piece - Removal & Installation (644 Body) 2
- Backrest Heater Pad - Removal and Installation (644 Body) 2
- Seats & Cushions - Removal & Installation (644 Body) 3
- Backrest mechanical cable for the power seat, replacing
- Installing backrest mechanical cable, power seats
- Backrest motor for the power seat, replacing
- Backrest, Replacing
- Preparatory work
- Installing the front seat backrest
- Installing the front seat
- Components Backrest, Replacing
- Removing seats
- Removing the backrest padding
- Installing the adjustable lumbar support
- Installing the backrest padding
- Installing the backrest upholstery
- Installing head restraints
- Front seat, replacing
- Lifting out the front seat
- Lifting in the front seat
- Finishing
- SRS connector
- Heater pad backrest, replacing
- Removing the front seat
- Types of heater pad
- Removing upholstery
- Installing seats
- Heater pad seat cushion
- Removing old heater pads
- Positioning the heater pad
- Positioning in relation to the channels in the foam filling
- Finishing work after the heater pad has been bonded into place
- Installing upholstery
- Motors under the seat for the power seat, replacing
- Installing the motor
- Power seat base, replacing
- Replacing the front seat head restraints
- Removing front seat head restraints
- Removing the upholstery from the front seat head restraints
- Seat cushion, replacing
- Installing the seat cushion padding
- Seat heater module, replacing
- Removing the control module
- Installing the control module
- Seat rail base, replacing
- Side panel and control panel power seat, replacing
- Installing the control panel
- Side Panel, Replacing
- Whiplash element, replacing
- Removing seats and upholstery
- Removing the whiplash element
- Installing seats and upholstery
- Removing backrest upholstery
- Removing the plastic plate from the backrest frame
- Removing the SIPS airbag from the backrest
- Installing the SIPS airbag on the backrest
- Installing the plastic plate in the backrest frame
- Installing the soundproofing
- Information
- Installing the front floor carpet. Right or left
- Installing the grab handle
- Preparations
- Installing the headlining
- Installing components
- Final check
- Installing the rear floor carpet
- Removing the bracket for the sun visor
- Installing the bracket for the sun visor
- Installing the sun visor
- Driver's side soundproofing
- Front floor carpet
- Grab handle front
- Removing components
- Removing the headlining
- Parcel shelf sun blind
- Parcel shelf, 4-door cars
- Passenger side soundproofing
- Rear floor carpet
- Sun visor
- Headlining
- Backrest upholstery
- Backrest rear seat, upholstery, removing
- Handle and panel, removing
- Installing rear head restraint (L and R) upholstery
- Installing rear head restraint (L and R)
- Removing middle head restraint upholstery
- Installing middle head restraint upholstery
- Installing backrest
- Replacing armrest upholstery
- Removing rear seat head restraint
- Installing rear seat head restraint
- Replacing rear head restraint (L and R) upholstery
- Removing/installing rear seat upholstery
- Replacing seat upholstery
- Installing the (lower) panel on the A-post
- Installing the lower B-post panel
- Rear seats
- Tailgate panel
- Installing the upper panel for the A-post
- Engine Controls - Basic Diagnostic Procedures 2
- Engine Controls - Trouble Shooting - No Codes 2
- Engine Controls - System & Component Testing 2
- Dynamic Stability Assist (Dsa) & Electronic Control Module (ECM) Diagnostic Trouble Codes (644 Body) 4
- Electronic Control Module (ECM) Diagnostic Trouble Codes - 1 of 3 (644 Body) 4
- Electronic Control Module (ECM) Diagnostic Trouble Codes - 2 of 3 (644 Body) 3
- Electronic Control Module (ECM) Diagnostic Trouble Codes - 3 of 3 (644 Body) 3
- Engine Control Module (ECM) - Diagnostic Trouble Code (DTC) Index - B4204T3 (644 Body)
- Volvo Scan Tool - Connection (644 Body)
- Volvo Communication Tool (Vct 2000) - Connection (644 Body) 2
- Diagnostic Trouble Code (DTC) Information & Dsa Signal Description (644 Body)
- Diagnostics & Fault Tracing - Description & Operation (644 Body) 3
Transmission Mechanical & Lubrication - Removal, Installation, & Inspection (644 Body)
22 subsections- Checking the function of the clutch
- Check the center of the clutch driven plate (splines)
- Check the oil
- Oil level, checking (2000)
- Preparing to check the oil level
- Move the gear selector through all positions. Wait in each position for approximately 3 seconds
- Top up with oil through the dipstick pipe
- High level (overfilling)
- Transmission, removing (M56)
- Slacken off the drive shaft nut on the left side
- Lower the engine until the distance between the lifting beam and the lifting eyelet is approximately 200 mm.
- Transmission, removing/installing
- Removing components left and right-hand sides
- Installing transmission
- Installing splash guards and wheels
- Installing gear selector cable
- Checking transmission oil level
- Checking oil level
- Removing components
- Disconnect the battery lead
- Install the lifting beam and the lifting hook on the engine lifting lugs
- Preparatory work for removing the wheel spindle on the left-hand side
- Oil, Changing
- Conditions for changing
- Filling, Continued
- Checking the Oil Level
- Preparations, continued
- Installing components
- Installing other components
- Filling and checking oil
- Replacing the carrier plate
- Preparatory work
- Removing the carrier plate
- Finishing
- Removing the air cleaner (ACL) housing, the intake manifold and the battery
- Installing the connector on the transmission bracket
- Installing the air cleaner (ACL) housing, the intake manifold and the battery
- Replacing the boot and/or indicator panel
- Removing the air cleaner (ACL) housing and intake manifold
- Adjusting the gear-shift position sensor
- Installing the air cleaner (ACL) housing and intake manifold
- Replacing the right and left-hand differential seals
- Replacing the sealing ring for the gear shift linkage rod
- Removing engine compartment components
- Removing the gear-shift position sensor from the gear shift linkage rod
- Installing the gear-shift position sensor
- Installing the gear-shift position sensor, continued
- Installing engine compartment components
- Replacing the sealing ring for the oil pump
- Removing the transmission
- Installing the transmission
- Preparations
- Checking the resistance of SLT, SLS and SLU
- Replacing solenoids S1-S5
- Installing the control system
- Installing the vehicle speed sensor (VSS)
- Installing the air cleaner (ACL) housing, the intake manifold and battery
- Replacing the transmission
- Detaching transmission connectors
- Removing the heat deflector plate and member
- Detaching the left-hand side drive shaft
- Detaching the right-hand side drive shaft
- Detaching oil pipes
- Lifting engine and transmission
- Installing the screws, transmission/engine
- Installing the front and rear brackets
- Installing the support member
- Installing the oil pipes
- Installing the shift cable
- Adjusting the gear cable
- Removing battery and air cleaner
- Removing passenger compartment components
- Installing the center console
- Adjusting shift cables, installing engine compartment components
- Shift lock and ignition switch interlock
- Conditions
- Check
- Removing center consoles
- Installing center consoles
- Replacing boot/indicator panel
- Replacing the kickdown switch (KD)
- Replacing the S and W mode selectors
- Installing the control module
- Opening the control system
- Replacing accumulator pistons/sealing rings B2/C2
- Opening control system
- Removing sticking valves and pistons
- Reinstalling control system
- Replacing accumulator pistons/sealing rings C3
- Information for work with valves and pistons
- Replacing control system
- Cleanliness
- Disconnecting connectors
- Sealing cover
- Replacing left-hand side drive shaft seal
- Installing stub axle, brake hose and ABS line
- Adjusting and checking
- Replacing right-hand side drive shaft seal
- Removing components
- Installing drive shaft
- Install cover
- Installing splash guards and wheel
- Replacing the engine speed (RPM) sensor
- Replacing the gear-shift position sensor
- Removing the gear-shift position sensor
- Removing transmission
- Oil pump sealing ring
- Installing transmission
- Readings, solenoids
- Replacing solenoid
- Removing the battery and air cleaner (ACL)
- Installing the gear selector cable
- Installing the rear center console
- Adjusting the transmission cable. Installing engine compartment components
- Replacing the primary shaft seal
- Installing the clutch cylinder
- Removing the clutch cylinder
- Installing the extractor for the primary shaft seal
- Installing the new primary shaft seal
- Install the rubber pipe seal in the clutch cover
- Checking the shift lock function
- Install the control module
- Removing the components on the left and right-hand sides
- Disconnecting the drive shaft, left-hand side
- Connecting the fixture
- Installing
- Install the AC compressor
- Installing left/right drive shafts
- Checking the drive shafts
- Install the hose to the charge air cooler (CAC)/charge air pipe
- Installing the splash guards and wheels
- Install the Poly V-belt
- Install the engine compartment components
- Checking the transmission oil level
- Installing the engine with the transmission
- Removing the engine with the transmission
- Adaptation of Transmission control module (TCM)
- Check the cable terminal locking tabs
- Poor results after crimping
- Examples Of Incorrect Crimping
- Reason
- Example 1
- Insert new cable terminal
- Example 2A
- Crimp new cable terminal
- Insert new cable terminal in housing
- Example 2B
- Insert the new cable terminal in housing
- Example 3
- Extract the cable terminal
- Insert the new cable terminal in the housing
- Example 4
- Cable Terminals, Different Types
- Cable terminals are divided up into the following main groups
- (When the cable terminals are partly exposed with the locking tabs visible in the cavities)
- 3.5 Moisture proof Pin/Pin sockets
- Proceed to
- Primary locking in general
- Primary locking in cavities
- Without primary locking
- Cable terminals without locking tab
- Removing cable terminals with locking tabs
- Release the locking tab for the cable terminal as follows
- Glossary for connector/housings
- Terms used for cable terminals
- Environmental factors
- Surface Oxides
- After completing the repair work
- Proceed
- Secondary locking
- Separate the connector
- General instructions
- Types of catches and locks
- Reconnecting
- Open locking lid/catch
- Proceed as follows
- Open the housing
- Select a new cable terminal
- SWS (Single Wire Seal)
- Select a suitable crimp tool for the cable terminal
- Crimp the cable terminal
- Checking crimping of a cable terminal
- Insert the cable terminal in the housing
- Close the housing
- New Cable Terminal
- If no similar cable terminal is available in the cable terminal assortment
- Soldering, General
- Cable Terminals Kit, P/N 9814234
- Cable Terminals Box, P/N 9814232
- Crimp tool
- Cable Terminals Kit, P/N 9814233
- Repair kit, p/n 9814235
- Uninsulated cable terminals
- Core wings and insulation wings
- Core crimp - electrical efficiency
- Core crimp - mechanical efficiency
- Correct choice of crimp tool for a cable terminal
- Crimp tool (black), p/n 9814223
- Crimp tool (red), p/n 9814224
- Crimp tool (yellow), p/n 9814225
- Crimp tool (green), p/n 9814226
- Crimp tool (blue), p/n 9814227
- Crimping a cable terminal
- Use a Volvo crimp tool
- Advantages of terminal crimping
- Terminal crimping, method and tools